Beginner’s Guide to SOLIDWORKS 2016 ®

Level I

Parts, Assemblies, Drawings, PhotoView 360 and SimulationXpress

Alejandro Reyes MSME, CSWE, CSWI

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Special Features

Special Features: Sweep, Loft and Wrap There are times when we need to design components that cannot be easily defined by prismatic shapes. For those features that have ‘curvy’ shapes we can use Sweep and Loft features, which let us create almost any shape we can think of. These are the features that allow us to design consumer products, which, more often than not, have to be visually attractive and pleasant to touch, making extensive use of curvature and organic shapes. These products include things like your remote control, a computer mouse, a coffee maker, perfume bottles, telephones, etc., and more often than not, their commercial success can be directly attributed to their appearance. They have to look nice, ‘feel’ right, and of course perform the task that they were intended for. Sweeps and Lofts (also used to create “organic” shapes like those found in nature) are widely used in the automotive, consumer products and aerospace industry, where cosmetics, aerodynamics, and ergonomics are very important in the design. Sweeps and Lofts have many different options that allow us to create anything from relatively simple to extremely complex shapes. In light of the vast number of variations and possibilities for these features, we’ll keep these examples as simple as possible without sacrificing functionality, to give the reader a good idea as to what can be achieved. Sweeps and Lofts are usually referred to as advanced features, since they usually require more work to complete, and a better understanding of the basic concepts of solid modeling. Having said that, these exercises will assume that commands that we have done more than a couple of times up to this point, like creating a sketch, are already understood and we’ll simply direct the reader to create it providing the necessary details. This way we’ll be able to focus more on the specifics and options of the new features. The Wrap feature is a special tool that helps us, as the name implies, to 'wrap' a sketch around a cylindrical surface, this tool helps us create features like cylindrical cams, slots on cylinders or cylindrical surfaces, etc.

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These are some examples of designs made using advanced modeling techniques.

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Sweep: Cup and Springs

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Notes:

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The Cup For this exercise we are going to make a simple cup. In this exercise we will learn a new option when creating features called “Thin Feature,” the Sweep command, a new Fillet option to create a Full Round fillet and a review of auxiliary Planes. The sequence of features to complete the cup is:

Revolve Thin

Create Path Sketch

Auxiliary Plane

Create Profile Path

Make Sweep

Cut inside of Cup

Full Round Fillet

Handle Fillet

8.1. - For the first feature we will create a “Revolved Feature” using the “Thin Feature" option. This option makes a feature with a specified thickness based on the sketch that was drawn. Select the "Front Plane" and create the following sketch. Notice the sketch is an open profile with two lines, an arc and a centerline. (Remember to make the diameter dimension about the centerline.) Thin Features can be made using either an open or closed sketch, but using an open sketch will always make a thin feature.

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8.2. - After selecting the “Revolve Boss/Base” command we get a warning telling us about the sketch being open. Since we want a thin revolved feature, select “No".

In the “Revolve” options, “Thin Feature” is automatically activated. Since we want the dimensions we added to be external model dimensions, select the Thin Feature’s “Reverse Direction” option to add the material inside the cup. Notice the preview showing the change. Click OK to finish the first feature. In the value box we typed 3/16; we can add a fraction and SOLIDWORKS changes it to the corresponding decimal value when we click OK. We can also type simple mathematic expressions including addition, subtraction, multiplication, and division in any value box where we can type a value.

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Our part looks like this and “Revolve-Thin1” is added to the Feature Manager.

8.3. - Select the "Front Plane" and create the following sketch using an ellipse. Switch to a Front view and select the “Ellipse” command from the Sketch tab in the CommandManager, or from the menu “Tools, Sketch Entities, Ellipse". To draw an ellipse, first click to locate its center, click again to locate one axis and again to locate the other axis. Add the corresponding dimensions between the ellipse’s points at the major and minor axes. Be sure to add a “Vertical” geometric relation between the top and bottom points of the ellipse (or “Horizontal” between left and right) to make them vertical (or horizontal) to each other to fully define the sketch.

When looking at a round surface’s profile from an orthogonal view we can add a dimension to its silhouette.

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Exit the sketch and rename it "Path Sketch.” We will not use the sketch for a feature just yet.

8.4. - Create an Auxiliary parallel plane using the "Right Plane" as the first reference and the center of the ellipse as the second reference as shown. Click OK to finish the plane.

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8.5. - Select the plane just created and draw the next sketch in it. Looking at the plane perpendicular to it helps us better visualize the sketch. After adding the sketch, select the plane and press the “Normal To” command (shortcut Ctrl+8). Pressing it again will show the reverse view. “Normal To” can also be selected from the pop-up menu after selecting the plane. Start the center of the new ellipse at the top point of the previous sketch's ellipse. Add a coincident relation if needed. Remember to add a horizontal relation between the points of the major (or vertical to the minor) axis. If necessary, rotate the view to have a better view and select the top point of the previous sketch’s ellipse. Exit the sketch and rename it “Profile Sketch.”

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8.6. - Select the “Sweep” icon from the Features tab in the CommandManager or from the menu “Insert, Boss/Base, Sweep.” The sweep is a feature that requires a minimum of two sketches: one for the sweep’s profile and one for the path. (For the path of the sweep instead of a sketch we can also use a model edge or a user defined curve that cross the profile.)

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In the “Sweep” properties, select the "Profile Sketch" in the Profile selection box, and the "Path Sketch" in the Path selection box. Optionally, a Sweep can have guide curves and other parameters to better control the resulting shape; in this case we are making a simple sweep feature. Notice the preview and click OK when done to finish the sweep. Hide the auxiliary plane using the “Hide/Show Items” toolbar if so desired.

It may be necessary to turn on the “Merge Tangent Faces” checkbox under “Options” to have a single continuous sweep surface. 8.7. - Notice the sweep also goes inside the cup. To fix this we’ll make a cut. Create a sketch in the flat face at the top of the cup.

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Select the inside edge at the top and use “Convert Entities” from the Sketch tab to convert the edge to sketch geometry. Click OK to continue.

8.8. - Select the “Extruded Cut” icon and use the “Up to next” end condition from the drop down selection list. This end condition will make the cut until it finds the next face (the bottom) effectively cutting the part of the handle inside the cup.

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8.9. - Now we need to round the flat face at the top lip of the cup. To do this we’ll add a “Fillet” using the “Full Round Fillet” option. The full round will essentially remove the flat face at the top (the middle face), and replace it with a rounded face tangent to both the start and end faces.

Before

After

We need to select three faces, the middle face will be the one replaced by the fillet. After selecting the Fillet command, select the "Full round fillet" option to reveal the selection boxes. With the first selection box active select the outside face of the cup. Click inside the second selection box and select the top flat face of the cup. Click inside the third selection box and select the inside face of the cup. Note the selected faces are color coded. When done selecting faces click OK to apply the fillet.

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8.10. - To finish the cup add a fillet to round the edges where the handle meets the cup. Select the fillet command with the “Constant Radius” option, select the handle's surface, and change the radius to 0.25″. Click OK to finish.

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8.11. - Save the finished part as ‘Cup’ and close.

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Notes:

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Simple Spring In the next exercise we are going to show how to make a simple and a variable pitch spring. In order to make these springs we’ll have to learn how to make a simple and a variable pitch helix to be used as a sweep path. The sequence of features to complete the springs are: Simple Spring

Draw circle

Draw Spring Profile Sketch

Make Helix

Make Sweep

Variable Pitch Spring

Draw circle

Make Variable Pitch Helix

Draw Spring Profile sketch

Make Sweep and cut ends

9.1.- In order to make a helix, first we need to make a sketch with a circle. This circle is going to be the helix’s diameter. Select the "Front Plane" and make a sketch using the following dimensions. Exit the sketch when done.

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9.2. - In the Features tab select “Curves, Helix and Spiral” from the drop-down icon or the menu "Insert, Curve, Helix/Spiral.” If asked to select a plane or a sketch, select the sketch we just drew.

If we don't exit the sketch, we'll only have the "Helix and Spiral" option from the "Curves" command. If we select the “Helix and Spiral” before exiting the sketch, it will be automatically selected. The helix is defined from two parameters between Pitch, Revolutions, or Height, and the third parameter is automatically calculated from the other two. For this example we'll select “Pitch and Revolution” from the “Defined By:” drop down menu, make the pitch 0.325" with 6 Revolutions. The “Start Angle” value defines where the helix will start. By making it 90 degrees it will start at the top, coincident with the “Front Plane.” If we had made it 0 degrees, it would be coincident to the "Top Plane" instead. (Feel free to explore the options.) Click OK to finish the helix.

Note the Helix command has options to make it Counterclockwise, Clockwise, Tapered, Variable pitch and reversed (going right or left).

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9.3. - Once the Helix is done, we need to make the profile sketch for the sweep. Switch to a Right view, and add a new sketch in the "Right Plane" as shown. Make the circle close to the Helix…

… and add a “Pierce” geometric relation between the center of the circle and the helix. This way the path will start at the beginning of the helix. This relation will make the sketch fully defined. Exit the sketch when done.

A pierce relation is done between an element that is oblique or perpendicular to the sketch plane and a point in the sketch. Think of it as a needle piercing through a fabric, the sketch being the fabric and the helix (or curve, model edge or another sketch element) the needle. 231

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9.4. - Select the Sweep command and make the sweep using the last sketch as a profile and the Helix as a Path. Note the Preview and click OK to finish.

Save as 'Spring' and close the finished spring.

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Variable Pitch Spring 10.1. - For the variable pitch spring we’ll start the same way and make the following sketch in the "Front Plane". This will be the spring’s outside diameter.

10.2. - While still editing the sketch, in the Features tab from the “Curves” drop down icon select “Helix and Spiral”; notice it is the only option available. In the Helix/Spiral command select “Pitch and Revolution” from the “Defined by:” selection box and “Variable Pitch” in the Parameters box. After selecting it we are presented with a table, fill in the values for the helix using the next table. Click OK when finished to build the helix.

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10.3. - After the helix is complete add a new sketch in the “Right Plane.” Draw the circle first, then add a center rectangle, trim and dimension as needed. Locate the sketch to the either side of the helix.

Add a centerline from the center to the top line (make sure it is coincident). Add a “Pierce” geometric relation between the top endpoint of the centerline and the helix to fully define the sketch. Exit the sketch and optionally rename it 'Profile'.

The Pierce relation allows us to fix the profile to the path, and can be added to any part of the sketch. We chose to add it to the top because the original sketch used for the helix is the spring's outside diameter. 10.4. - Just as we did before, select the "Sweep" command, add the path and profile as shown and click OK to finish.

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10.5. - As a finishing touch we’ll make a cut to flatten the sides of the spring. Change to a Right view and add a sketch in the “Right Plane.” Draw a single line starting at the midpoint of the indicated edge and long enough to cross the part.

10.6. - Select the “Extruded Cut” command; if we use an open sketch to make a cut, selecting either the "Through All" or the “Through All - Both” option, automatically activates the “Direction 2” checkbox with the “Through All” end condition and one side of the model is cut using the open sketch. The small arrow located at the center of the line indicates which side of the model will be cut. Use the “Flip side to cut” option if needed to cut the left side. Click OK to complete the cut, and repeat the same sketch and cut-extrude in the right side. Note the cutting plane is shown in the graphics area.

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When using an open sketch to cut a model, we can only use a single open profile. If we have multiple open profiles we cannot make the Cut Extrude using these options, we would get multiple thin cuts with a different behavior. 10.7. - Save the model as 'Variable Pitch Spring'.

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Thread Feature Threads can be added to a model either by adding a Sweep Boss with a helix, a Sweep Cut with a helix or using the “Thread” tool. When modeling screws and fasteners in general, it is almost always unnecessary to add a helical thread, as it consumes a large amount of computing resources, and a simple representation using a Revolved Boss/Cut or a Cosmetic Thread is usually enough. It is strongly advised to only add threads when required by the model, as in the bottle exercise in this lesson. 11.1. - To learn how to use the “Thread” command open the part ‘Threads’ from the accompanying files. This part has two cylinders, the first one (Blue) is the size of a ¼20 screw’s minor diameter, and the second (Green) is the size of a ¼-20 screw’s major diameter. The hole (Pink) is the size needed to make a ¼-20 tapped hole. The “Thread” command is located in the menu “Insert, Features, Thread.” This command allows us to select a standard thread size and apply it either as an external thread (male) to a cylindrical boss or an internal thread (female) to a hole.

There are two ways to add an external (male) thread: The first way is to add (extrude) the thread in a cylinder the size of the thread’s minor diameter. The second way is to start with a cylinder the same size as the screw’s major diameter and cut away the thread. 237

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Extrude Thread added to Minor Diameter

Cut Thread removed from Major Diameter

11.2. - Select the Blue cylinder’s top edge to add the thread, in this case we’ll add the thread using the following settings, click OK when done to finish the thread feature: • Thread Location is to the edge to start the thread. Select the top edge of the blue cylinder’s face. • End Condition: The thread’s length, number of revolutions or up to surface. Set to “Blind” and define its length to 0.375”. • Specification is the standard and size of the thread. Select “Inch Tap” to add a thread, and “0.2500-20” to define the thread size as ¼-20. • In Thread Method use the “Extrude thread” to add the thread on top of the cylindrical face. • In Thread Options select Right-hand thread.

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Our first finished thread looks like this:

11.3. - The illustrate the second way to add an external thread, in this step the thread will be added to the green cylinder using the same settings as the previous one, except under “Specification” we’ll use the “Inch Die” and “Cut thread” options to cut into the cylinder instead of adding material.

Another option that will be changed in the second thread is to turn on the “Offset” option under “Thread Location,” the reason to turn this option ON is to have a thread that starts to cut the cylinder outside, making a more true-to-life thread. Change the direction of the offset and make it 0.040” as indicated, this way the thread will be cut starting away from the face. Optionally we can also control the angle where the thread starts by changing the “Start Angle” value.

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Offset option OFF

Offset option ON

11.4. – The last thread we’ll be making is the internal (tapped) thread. In this case the hole in the part has a 0.201” diameter (#7 drill bit), this is the drill size we’d use in real life to make a ¼-20 tapped hole. Select the “Thread” command, and this time select the pink hole’s edge. The options we’ll use are: • • • • •

Thread Location, select the edge and turn on the “Offset” option to have the same result as in the previous step to start the thread outside the hole. In Specification select “Inch tap”, size “0.2500-20” Thread Method use the “Cut thread” option to cut into the part. For End Condition select “Up To Selection,” and select the face at the other end of the block to make the thread go through the entire block. Under Thread Method select “Cut thread”

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Looking at the part from a Top view using the Hidden Lines Visible option we can see that the external threads fit inside the tapped hole.

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Sweep: Bottle

For the next exercise we'll build the following bottle using a sweep feature with guide curves.

*Image made using RealView graphics In this model we’ll use two sweep features, one for the body and one for the thread. For the body we'll make a sweep with two guide curves, so we need to make four sketches: Path, Guide Curve 1, Guide Curve 2 and Profile, in that order. The reason to make the Profile last is that it has to pierce the Path and both Guide Curves for the sweep feature to work as expected. 243

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12.1. - Open a new part, set dimensions to inches, and three decimal places. Make the Path sketch in the "Front Plane" and Exit the sketch. Rename 'Path'.

12.2. - Add a second sketch in the “Front Plane.” Make arcs and lines tangent to each other; add centerlines as reference for tangency. All arcs are equal. Exit sketch and rename 'Guide 1'.

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12.3. - Add a third sketch in the “Right Plane.” Add geometric relations to previous sketches to maintain design intent. Make the topmost endpoint Horizontal to the topmost endpoint of the 'Path' sketch. Arcs are equal size and tangent. Make the indicated endpoints horizontal. Only geometric relations and two dimensions are needed to fully define the sketch. Exit the sketch and rename it 'Guide 2.'

Right view

View between front and right

12.4. - Add a new sketch in the “Top Plane.” Make an ellipse in the origin adding Pierce relations between the ellipse's major and minor axes to 'Guide 1' and 'Guide 2'. View is in Isometric for clarity. Exit the sketch and rename it 'Profile'.

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12.5. - Select the "Sweep Boss/Base" icon, add the 'Path' sketch to the "Path" selection box and the 'Profile' sketch to the "Profile" selection box. Expand the "Guide Curves" selection box and add both guides to it. Click OK to finish.

12.6. - Add a sketch on the top face, use "Convert Entities" to project the edge of the top circular face…

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…and extrude it 1".

12.7. - Using the fillet command, add an asymmetric fillet at the bottom edge. An asymmetric fillet allows us to define a different distance for each side of the fillet. Activate the option and set the first distance to 0.375" going up, and 0.25” at the bottom of the bottle.

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12.8. - Add a 0.050" shell to the part removing the top face.

12.9. - Add a parallel auxiliary plane 0.125" below the topmost face.

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12.10. - Add a sketch in the new plane. Use “Convert Entities” to project the top outside edge and make a Helix defined by Pitch and Revolution using 0.2" for pitch and 2.5 revolutions. Make sure the Start Angle is set at 0 degrees.

12.11. - Rotate to a Right View and add the following sketch in the "Right Plane", this will be the thread’s Profile. For the vertical line we’ll use a “Midpoint Line”, the point at the middle of the line will be used to add a horizontal relation with the arc’s center point, and also a Pierce relation to the helix. Draw, dimension and add the geometric relations indicated, then Exit the sketch and make a sweep feature using the helix and this thread profile. After creating the sweep, if needed, hide the helix curve.

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Horizontal Relation

Add Dimensions

Add Pierce Relation

Finished Sketch

Hide the Helix (if needed)

Finished Sweep 250

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12.12. - Add a sketch to the flat face at the beginning of the thread using “Convert Entities”. Make a 120 degrees "Revolved Boss" using the vertical edge as axis of revolution. The reason to make it 120 degrees is to completely merge it with the body of the bottle. Add another sketch at the end of the thread and repeat the same process.

12.13. - Add a 0.02" fillet to the thread as a finishing touch. You may need to select multiple edges. Save the part as ‘Bottle’ and close it.

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Engine Project Parts: Make the following components to build the engine. Save the parts using the name provided. High resolution images are included on the exercise files.

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Loft: Bottle

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The “Loft” feature requires at least two different sketches and/or faces and optionally guide curves to more accurately define the final shape. The Loft helps us design complex shapes with more control over the cross section. In this exercise we will make a bottle using a loft with four different sketches. 13.1. - Make a new part and create three auxiliary planes using the “Plane” command. Select the "Top Plane" as reference, change the number of planes to 3 and space them 2.5″ as shown. Click OK when done.

13.2. - For clarity, select the "Top Plane" in the FeatureManager and show it using the “Hide/Show” command from the pop-up toolbar. Turn on Plane visibility if needed in the “Hide/Show Items” command.

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13.3. - Switch to a Top view, select the "Top Plane" and draw the following sketch using the “Center Rectangle” and “Sketch Fillet” tools. Exit the sketch when finished. Plane visibility was turned off for clarity.

Turn off Plane visibility for clarity using the “Hide/Show Items" menu.

13.4. - Still in the Top view, select “Plane1” in the FeatureManager and create the second sketch. Use the "Center Rectangle" tool; be sure to start in the origin and make the rectangle's corner coincident to the previous sketch's diagonal line. Add a 2.5″ width dimension and the 0.5″ “Sketch Fillet” to fully define the sketch. Exit the second sketch when finished.

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13.5. - For the third profile, select “Plane2” from the FeatureManager and create a new sketch in it. This sketch will be exactly the same as the first one. To help us save time and maintain design intent, we'll use the “Convert Entities” tool. In the “Convert Entities” selection box, select “Sketch1” from the fly-out FeatureManager and click OK to project “Sketch1” in the new sketch. Exit the sketch when done.

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13.6. - For the last profile select “Plane3” from the FeatureManager and create a new sketch. Draw a circle and add a geometric relation to make it “Tangent” to the horizontal line in “Sketch2” as indicated. This relation will fully define the sketch. Exit the sketch to finish.

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The finished sketches will look like this with the planes visible:

13.7. - Now we are ready, select the “Loft” icon from the Features tab. The loft feature requires two or more sketches and/or faces, and we'll use the four sketches we just made to build the bottle.

We will select the profiles in order starting with the first one we made at the bottom and finishing with the last one at the top (or from top to bottom, but in order). It is important to select the sketches thinking that where we select the profile will affect the result. Click in the graphics area near the indicated ‘dots’, this line indicates the segment of one profile that will be connected to the next profile. If we 261

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select points randomly in the profiles, the loft could twist and produce undesirable results. Optionally guide curves can be added to improve control of the resulting shape. From the “Start/End Conditions” select “Normal to Profile” for both the “Start” and “End” constraint. Notice the difference in the preview after selecting the start and end constraints. Click OK when done.

Optionally, turn on the curvature display for the preview, this will allow you to better visualize the final shape using a mesh, zebra stripes and/or curvature combs. The zebra stripes helps us to better visualize the continuity of the curvature in surfaces, particularly useful in consumer product design.

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13.8. - Add a 0.25″ radius fillet in the bottom edge of the part to round it off.

13.9. - Add a 0.75” extrusion at the top of the bottle and finish using the “Shell” command removing the top face making the wall thickness 0.125.″

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Image using Real View

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13.10. - To view the inside of the part, select the “Section View” icon from the View toolbar or the menu "View, Display, Section View". We can define which plane to cut the model with, the depth of the cut and optionally add a second or third section. If we click OK in the Section View, the model will be displayed as cut, but this is only for display purposes; the part is not actually cut. To turn off the Section View, select its icon or menu command again. This section view can be used along with the “Measure” tool to inspect the part.

The depth of the section can be changed by changing the distance in the PropertyManager or by dragging the arrow in the center of the plane. The section view plane’s rotation can also be changed by dragging the rotation handles or entering a value in the rotation value boxes.

Save the part as 'Bottle Loft' and close.

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Wrap Feature

The wrap feature helps us create cylindrical cams or slots on cylindrical surfaces using a sketch on a plane tangent to the surface we want to make the wrap on. 14.1. - Make a new part, set units to inches with three decimal places; add this sketch on the "Front Plane" and extrude it 3". Be sure to add a Point at the top of the circle, this point will be used later to add an auxiliary plane.

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14.2. - The next step is to make the sketch that will be used for the wrap feature. For the sketch plane we’ll make a new plane parallel to the "Top Plane" tangent to the cylindrical surface. Make the sketch of the first feature visible, and add a new plane parallel to the “Top Plane” and coincident to the point in the first sketch. Hide the first sketch when done.

14.3. - Add a new sketch in the new plane and draw the following profile. Make sure it’s symmetrical about the centerline. All arcs are equal radii. The top dimension's value is entered as 1.5 * pi, since we want the sketch to wrap completely around the cylinder. After entering the equation the resulting value is calculated. To make the sketch symmetrical as we draw it, draw the centerline first, preselect it, and turn on the “Dynamic Mirror” command in the menu “Tools, Sketch Tools, Dynamic Mirror.” To know that we have a Dynamic Mirror active SOLIDWORKS adds an equal (=) sign at both ends of the mirror centerline. When the mirror is active, everything we draw on either side of the mirror line will be automatically duplicated in the other side adding a Symmetric geometric relation at the same time.

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For the Dynamic Mirror command we can pre-select a centerline, line or a model’s linear edge

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14.4. – So far the sketch is the centerline of the slot we are going to wrap around the cylinder. Select the "Offset" command from the Sketch tab and turn on the following options: • • • •

"Select chain" to automatically select the entire centerline when we pick only one segment "Bi-directional" to make the offset in both directions "Make base construction" to change the selected line (or chain) to construction geometry And after selecting a segment of the sketch the "Cap ends" option is enabled, letting us choose to cap the offset with either Arcs or Lines.

Making the offset 0.25" will give us a 0.5" wide slot. Click OK to complete the offset. Note how the previously drawn sketch lines are now changed to construction geometry and now we have a closed (capped) profile. Exit the sketch when done.

14.5. - Select the “Wrap” feature from the Features tab or the menu “Insert, Features, Wrap.”

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If the sketch is not pre-selected, select the sketch from the graphics area or the fly-out FeatureManager.

In the “Warp” command properties select the "Deboss" option to make a cut in the part. (The "Emboss" option will add material and "Scribe" will split the face.) Select the cylinder's face in the "Face for Wrap Feature" selection box, and make the depth 0.1". Click OK to finish. *As of the writing of this book if the option “Reverse Direction” is not activated, the Wrap feature fails in this case.

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14.6. - Add a 0.02" fillet to the wrap feature to finish the part and save it as 'Cylindrical Cam'.

*Finished part image made using Real View

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Exercises: Build the following parts using the knowledge acquired in this lesson. Try to use the most efficient method to complete the model. Eccentric Coupler Notes:

• • • •

Both circles are centered horizontally (Right view). Add a guide sketch at the bottom. Set the Start and End Conditions for the loft to “Normal to Profile". Make as Thin Feature or Shell it after making the loft feature.

HINTS: • • • • •

Draw the 1" circle in the "Right Plane". Make an Auxiliary Plane 6" parallel to the "Right Plane". Draw a 2" circle in the Auxiliary Plane. Draw a sketch in the "Front Plane" to make the guide curve. Select the guide sketch in the "Guide Curves" selection box.

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Guide sketch

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Bent Coupler Build the following part using a Loft feature and a shell. The part is 0.15″ thick. Notes:

• • •

Add a guide sketch along the right side of the part. Start and End Conditions “Normal to Profile". Make as Thin Feature or Shell after loft.

HINTS: • Make Rectangular sketch first. • Make Guide sketch. • Make Auxiliary Plane perpendicular to Guide sketch at the end point. • Make circular sketch in Auxiliary Plane. • Make Loft using Guide sketch as a guide curve. • Shell the part. 274

Guide sketch

Special Features

Challenge Exercises: Build the 'Worm Gear' and 'Offset Shaft' complete gears using the knowledge learned so far with the information given. High resolution images at www.mechanicad.com and www.sdcpublications.com.

Worm Gear Shaft Complete DISCLOSURE: The gears modeled in this tutorial are not intended for manufacturing, nor is this tutorial meant to be a gear design guide. Its sole purpose is to show the reader how to apply the learned knowledge using a simplified version of the gears.

15.1. - Offset Shaft: Open the previously made ‘Offset Shaft’ and add the following sketch in the "Front Plane"; Exit the sketch and rename it "Gear Width". This will be the length of the full size helix.

15.2. - Add two reference planes parallel to the "Right Plane,” one at each end of the "Gear Width" sketch.

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15.3. - Add the gear's profile sketch in the "Front Plane”, at the left side of the "Gear Width" sketch. Exit the sketch and rename it “Thread Profile.”

15.4. - In the plane located at the left of the "Gear Width" sketch add a new sketch; use the "Convert Entities" drop down icon to select "Intersection Curve", this command will create sketch entities at the intersection of the selected surface(s) and the current sketch plane. This tool is particularly useful when we have irregular surfaces intersecting the sketch plane. In this case it works the same as "Convert Entities", but for oblique or irregular surfaces it’s the best option to obtain the intersection of the surface and the sketch plane.

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15.5. - Use the Height and Pitch option to make the Helix 1" High with a 0.25" Pitch.

15.6. - Make the first sweep using the profile and the first helix.

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15.7. - In the plane at the right of the "Gear Width" sketch add a sketch for a second Helix using "Convert Entities” using the round edge of the shaft, and make the helix using the "Taper Helix" option with a 7deg taper to continue the previous helix.

15.8. - Add a sketch at the flat end of the thread using "Convert Entities" to use as the profile for the tapered helix (Rear view), and make the sweep.

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15.9. - Repeat a helix and sweep for the other side

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15.10. - Add a 0.015" fillet to round the edges of the thread. Save as 'Offset Shaft Gear' and close.

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Worm Gear Complete 16.1. - Worm Gear: Open the ‘Worm Gear’ part and change “Fillet1” to a 0.031” radius.

16.2. - Modify the following dimensions from the "Cut-Revolved2" feature and rebuild the model to continue.

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16.3. - Add a new plane 0.95" parallel above the “Top Plane.”

16.4. - Add the following sketch in the plane previously made; use the Midpoint Line tool and Exit the sketch. Rename it “Path.”

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16.5. - Add a new auxiliary plane perpendicular to the "Path" sketch. Rename it “Profile Plane.”

16.6. - Add this sketch in the "Right Plane" and make a revolved cut. Notice the doubled diameter dimension about the centerline. (Auxiliary planes have been turned off for clarity.)

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16.7. - In the "Profile Plane" add the following sketch. This will be the profile to make the gear cut. Press Ctrl+8 to view the plane normal to the screen. Locate the profile sketch adding a pierce relation to the "Path" sketch at the indicated point. Exit the sketch and rename “Gear Profile.”

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16.8. - Make a "Cut Sweep" using the "Path" and "Gear Profile" sketches. (In this particular case a "Cut Extrude" would give us the same result.)

16.9. - Add a 0.015" fillet at the bottom of the sweep cut.

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16.10. - Make a circular pattern with 22 copies of the Cut-Sweep and the fillet.

16.11. - After the pattern is complete add a 0.015" fillet to the "Groove" and "CutRevolve3" features to finish the gear. Save as 'Worm Gear Complete' and close.

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Engine Project Parts: Make the following components to build the engine. Save the parts using the name provided. High resolution images are included on the exercise files. Hint: Make a revolved boss with the option “Thin Feature.” Note the dimensions given are external.

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The 3 compression rings for the piston head.

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Final Parts for the Engine Project: The following components are the last required to complete the engine. Save the parts using the name provided. Suggested sequence of features for the Crank case top

Main body

Corner Fillets

Flange

Bearing mount boss

Mirror bearing mount

Shell part

Top cut

add 0.375" offset plane inside

Add inside bosses. Use Intersecting curve

Add front reinforcement

Add rear reinforcement

Add bearing mount

Add plane for oil dipstick

Add reference sketch for dipstick

Add plane at top of reference sketch

Add dipstick extrusion

Make hole for dipstick

Add sweep cut for threaded cap

Add fillets

Add holes and threads

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Crank Case Top Drawing (2 Pages)

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Oil Pan

Base extrusion

Fillet corners

Base flange

Bearing mount boss

Shell the part

Reinforcement

Screw mount reinforcements

Fillets

Add bearing mount

Add threads and screws

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Engine Block

Main body

First fin

Fin’s Pattern

Cuts for Intake/Exhaust

Base extrusion

Intake mount

Exhaust mount

Cylinder Bore

Mounting holes

Screw holes

Exhaust mount hole

Intake mount hole

Head mounting holes

Intake vent hole

Chamfer bottom holes

Round all edges

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Extra Credit: Visit our web site to download details for the Gas Grill project as well as the finished parts for this book, higher resolution images of the exercises and some extra topics not covered in the book. Build these components and after the Assembly lesson make the Gas Grill assembly.

http://www.mechanicad.com/download.html

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